Catheter having a soft distal tip

ABSTRACT

An intraluminal catheter comprising an elongated catheter shaft having proximal and distal ends and at least one lumen, and a tip member on a distal end of the catheter having a proximal end spaced distally apart from the distal end of the catheter shaft.

BACKGROUND OF THE INVENTION

This invention relates to the field of medical devices, and moreparticularly to a balloon catheter having a soft distal tip.

Catheters designed for intravascular procedures such as angioplasty havea number of design considerations. Such catheters must be able totransmit force along the length of the catheter shaft so that thecatheter can be pushed through the patient's vasculature. However, thecatheter shaft must also have sufficient flexibility to allow it totrack over a guidewire through tortuous vasculature. The catheter alsomust be able to cross stenosed portions of the vascular anatomy.

Prior art intravascular catheters have commonly included a soft distaltip to prevent or minimize injury to the vessel during advancement ofthe catheter therein. One difficulty has been forming a connectionbetween the soft tip and the catheter which is sufficiently strong toprevent disengagement of the soft tip or kinking at the junction betweenthe soft tip and catheter shaft. Additionally, it is necessary tobalance the strength of the connection between the soft tip and thecatheter shaft with the need to minimize the stiffness of the distal endof the catheter. Minimizing the stiffness of the distal end of thecatheter results in improved maneuverability of the catheter.

Accordingly, it would be a significant advance to provide a catheterwith a soft tip having improved performance. This invention satisfiesthese and other needs.

SUMMARY OF THE INVENTION

The invention is directed to an intraluminal catheter having a softdistal tip, and generally comprising an elongated catheter shaft havingproximal and distal ends, at least one lumen, and a soft distal tipmember secured to the distal end of the catheter having a proximal endspaced distally apart from the distal end of the catheter shaft.

One embodiment of the invention is a balloon catheter generallycomprising an elongated catheter shaft having an inflation lumentherein, a balloon on a distal shaft section in fluid communication withthe inflation lumen, and a soft distal tip member on a distal end of thecatheter. In accordance with the invention, the tip member has aproximal end spaced distally apart from the distal end of the cathetershaft. In one presently preferred embodiment, a distal shaft section ofthe balloon is bonded to the distal end of the catheter shaft, so thatthe balloon inflatable interior is spaced proximal to the distal end ofthe elongated catheter shaft. The balloon distal shaft section is alsobonded to the proximal end of the tip member, to thereby secure the tipmember to the distal end of the catheter. The tip member typically has alumen in fluid communication with a lumen of the catheter distal shaftsection.

The distal tip member is preferably softer than the catheter shaft, toprovide improved catheter maneuverability and decrease the risk ofdamage to the patient's vessel during advancement of the cathetertherein. The tip member is typically formed of a polymeric materialhaving a Shore Durometer hardness which is lower than the ShoreDurometer hardness of the polymeric material forming at least a sectionof the catheter shaft. The Shore Durometer hardness of the polymericmaterial forming the tip member is about 35D to about 63D, preferablyabout 40D to about 55D. In a presently preferred embodiment, the tipmember is formed of a polyether block amide polymer such as PEBAX(available from Autochem). However, the tip member may be formed of avariety of suitable materials, including polyolefin based copolymerssuch as a polyethylene based adhesive polymers such as anethylene-acrylic acid copolymer which is sold commercially as PRIMACORby Dow Chemical Co., and polyurethanes, such as polyurethane blockcopolymers such as PELLETHANE (a polyester based polyurethane, availablefrom Dow Plastics).

In accordance with the invention, the tip member has a proximal endspaced distally apart from the distal end of the catheter shaft. In oneembodiment, a gap exists between the distal end of the shaft and theproximal end of the tip member, and the balloon distal shaft sectionsurrounds and extends over the gap. In another embodiment, a portion ofthe balloon distal shaft section or an intermediate member is disposedwithin the space between the distal end of the catheter shaft and theproximal end of the tip member.

A method of forming a distal tip of the invention generally comprisespositioning a proximal end of the tip member within a balloon distalshaft section, so that the tip member proximal end is spaced distallyapart from a distal end of a catheter shaft which is also within theballoon distal shaft section, and fusion bonding the balloon distalshaft section of the catheter shaft and the tip member. In oneembodiment, the balloon material flows during fusion bonding into atleast a part of the space between the proximal end of the catheter shaftand the distal end of the tip member.

The catheter of the invention having a distal tip member spaced distallyfrom the distal end of the catheter shaft has excellent crossability andtrackability. The catheter has a smooth transition in stiffness alongthe distal end of the catheter at the distal tip member, to improvehandling and performance and minimize kinking. Additionally, thecatheter has good tensile strength at the tip member attachment, withoutdisadvantageously increasing the stiffness or profile of the distal endof the catheter. These and other advantages of the invention will becomemore apparent from the following detailed description and exemplarydrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevational view of a balloon catheter which embodiesfeatures of the invention.

FIG. 2 is an enlarged, longitudinal cross sectional view of the distalend of the catheter shown in FIG. 1, taken along lines 2—2.

FIG. 3 is a cross sectional view of the catheter shown in FIG. 2, takenalong lines 3—3.

FIG. 4 is a cross sectional view of the catheter shown in FIG. 2, takenalong lines 4—4.

FIG. 5 is a cross sectional view of the catheter shown in FIG. 2, takenalong lines 5—5.

FIG. 6 is an enlarged, longitudinal cross sectional view of an alternateembodiment of the catheter of the invention, having balloon shaftmaterial between the catheter shaft and tip member.

FIG. 7 is an enlarged, longitudinal cross sectional view of an alternateembodiment of the catheter of the invention, having an intermediatemember between the catheter shaft and distal tip member.

FIG. 8 is an enlarged, longitudinal cross sectional view of an alternateembodiment of the catheter of the invention, having a sheath surroundingthe distal end of the catheter and the proximal end of the distal tip.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a balloon catheter 10 embodying features of theinvention, comprising an elongated catheter shaft 11 having a proximalshaft section 12 and a distal shaft section 13, a tip member 14, aninflatable balloon 15 on the distal catheter shaft section 13 having aninterior 16, and an adapter 17 on the proximal catheter shaft section12. In the embodiment illustrated in FIG. 1, the catheter shaft 11comprises an outer tubular member 18 having an inflation lumen 19, andan inner tubular member 21 having a guidewire receiving lumen 22disposed within the outer tubublar member. Guidewire 23, illustrated inFIG. 1 within guidewire receiving lumen 22, extends to port 24 in thedistal end of the tip member 14. Balloon 15 has a working section 25, aproximal shaft section 26 disposed about and secured to a distal portionof the outer tubular member 18, and a distal shaft section 27.

As best illustrated in FIG. 2, showing an enlarged longitudinal crosssectional view of a distal section of the catheter 10 shown in FIG. 1taken along lines 2—2, the proximal end of the tip member 14 is spaceddistally apart from the distal end of the inner tubular member 21, andthus is not in contact therewith. In the embodiment illustrated in FIG.2, the distal end of the inner tubular member 21 is disposed distally ofthe inflatable interior 16 of the balloon. The balloon distal shaftsection 27 is disposed about a distal portion of the inner tubularmember 21 and a proximal portion of the tip member 14. In a presentlypreferred embodiment, the balloon distal shaft section 27 is secured toboth the distal portion of the inner tubular member 21 and the proximalportion of the tip member 14, as for example, by fusion bonding. Itwould be obvious to one of ordinary skill in the art that a sheath 40located distally adjacent to the distal end of the balloon distal shaftsection 27 could be disposed about and secured to the inner tubularmember 21 or tip member 14 in place of the distal end of the balloondistal shaft section 27.

As best illustrated in FIG. 2, tip member 14 has a lumen 28 in fluidcommunication with guidewire receiving lumen 22. FIGS. 3, 4 and 5illustrate transverse cross sectional views from the distal portion ofthe inner tubular member 21 to the proximal portion of the tip member 14of the catheter 10, taken along lines 3—3, 4—4, and 5—5, respectively.Tip member 14 is preferably a soft tip formed of a polymeric materialwhich is softer than the material forming at least the distal portion ofthe inner tubular member 21, which is secured to the balloon distalshaft section 27. The tip member 14 illustrated in FIGS. 2 and 5 isformed of a single layer of a material or a blend of materials. However,the tip member 14 may be a multilayered or multisectioned member (notshown).

In the embodiment illustrated in FIG. 2, a gap 31 is between the distalend of the inner tubular member 21 and the proximal end of the tipmember 14. Gap 31 is defined between and in part by a transverse surface33 of the distal end of the inner tubular member 21 and a transversesurface 34 of the proximal end of the tip member 14. Balloon distalshaft section 27 is in surrounding relation to the distal end of theinner tubular member 21, gap 31, and the proximal end of the tip member14, so that the balloon distal shaft section 27 extends over and in partdefines gap 31. As best illustrated in FIG. 4, showing transverse crosssection of the balloon distal shaft section 27 at the gap 31, the innerdiameter of the balloon distal shaft section is greater than the innerdiameter of the tip member 14.

In an alternative embodiment illustrated in FIG. 6, a portion 32 of theballoon distal shaft section 27 extends between the distal end of theinner tubular member 21 and the proximal end of the tip member 14. Theportion 32 is in contact with the transverse surfaces 33 and 34, and hasan inner surface 35 which defines a section of the guidewire receivinglumen 22. In the embodiment illustrated in FIG. 6, the inner surface 35of the portion 32 of the balloon distal shaft section 27 issubstantially axially aligned with the inner surface 36 of the tipmember 14. The phrase substantially axially aligned should be understoodto mean that the portion 32 of the balloon distal shaft section 27 andthe tip member 14 have the same inner diameter, or similar innerdiameters allowing for some slight variation in the inner surfaces35/36. In an alternative embodiment, the portion 32 of the balloondistal shaft section 27 may fill only a portion of the space between theinner tubular member 21 and the tip member 14, so that an inner portionof the gap 31 remains (not shown).

In another embodiment illustrated in FIG. 7, intermediate member 41 issecured to and extends between the distal end of the inner tubularmember 21 and the proximal end of the tip member 14. In the embodimentillustrated, the intermediate member 41 has a tubular shape with alength equal to the length of the space between the distal end of theinner tubular member 21 and the proximal end of the tip member 14. In apresently preferred embodiment, the intermediate member 41 is formed ofa polymeric material which has a Shore Durometer hardness which is lowerthan a Shore Durometer hardness of the inner tubular member 21 andhigher than that of the tip member 14. However, the softness of thematerial may vary depending on the length of the bond between theballoon distal shaft section 27 and the tip member 14, and the desireduse of the catheter 10. The intermediate member 41 can be made from avariety of suitable materials, such as a polyamide including a polyetherblock amide, and polyethylene based adhesive polymers includingethylene-acrylic acid copolymers such as PRIMACOR sold commercially byDow Chemical Co., and polyurethanes such as PELLETHANE. The intermediatemember 41 may be configured similar to the portion 32 of the balloondistal shaft section 27, as discussed above regarding the embodimentshown in FIG. 6. In the embodiment illustrated in FIG. 7, theintermediate member 41 has an inner surface substantially axiallyaligned with the inner surface 36 of the tip member 14 and an innersurface of the inner tubular member 21, as discussed above regarding theportion 32 of the balloon distal shaft section 27 shown in FIG. 6. Theintermediate member 41, and portion 32 of balloon distal shaft section27, preferably define annular lumens similar to those shown in FIGS.3-5.

The space is sufficiently long so that the polymeric materials formingthe inner tubular member 21 and tip member 14 do not flow into contactwith one another during fusion bonding of the balloon distal shaftsection 27 thereto. The length of the space (i.e., the length of gap 31,or portion 32, or intermediate member 41) between the distal end of theinner tubular member 21 and the proximal end of the tip member 14 mayvary depending on the desired catheter performance, the length of theballoon distal shaft section 27 and tip member 14, and the method usedto bond to tip member. The length of the space is typically about 0.05mm to about 0.75 mm, more preferably, from about 0.05 mm to about 0.3mm, preferably about 0.05 mm to about 0.5 mm, most preferably about 0.1mm to about 0.3 mm. In a presently preferred embodiment, the balloondistal shaft section 27 is about 1 to about 3 mm, preferably about 1.8to about 2.2 mm. The tip member 14 is typically about 1 to about 5 mm,preferably about 2 to about 3 mm. In the embodiment illustrated in FIGS.2, 6 and 7, the tip member 14 proximal end is distal to the longitudinalcenter of the balloon distal shaft section 27. However, in alternativeembodiments, the tip member 14 proximal end may be located in variousother locations along the length of the balloon distal shaft section 27(not shown).

The catheter shaft will generally have the dimensions of conventionaldilatation or stent deploying catheters. For coronary use, the length ofthe catheter 10 may be about 90 cm to about 150 cm, and is typicallyabout 145 cm. The outer tubular member 18 has a length of about 15 cm toabout 50 cm, an outer diameter (OD) of about 0.03 inch to about 0.05inch, and an inner diameter (ID) of about 0.031 inch. The inner tubularmember 20 has a length of about 15 cm to about 100 cm, an OD of about0.024 in and an ID of about 0.017 in. The inner and outer tubularmembers may taper in the distal section to a smaller OD or ID. Althoughnot illustrated, the catheter shaft inner tubular member, or outertubular member, may be made of multiple shaft sections joined together.

A method of forming a distal tip of a balloon catheter comprisespositioning a proximal end of a tip member and a distal end of acatheter shaft within a lumen of a balloon distal shaft section, so thatthe proximal end of the tip member is distally apart from the distal endof the catheter shaft. The balloon distal shaft section is fusion bondedto the catheter shaft and the tip member by applying heat to at least aportion of the balloon distal shaft section, to form a balloon catheterdistal tip having the tip member proximal end fusion bonded to theballoon distal shaft section and spaced distally apart from the distalend of the catheter shaft. Typically a mandrel is positioned within theinner tubular member lumen 22 and the tip member lumen 28 before thefusion bonding. In a presently preferred embodiment, a laser is used toheat the material for fusion bonding, and laser parameters such as focallength and power are selected to provide the desired heat spread. Thefocal length is typically about 2.6 to about 3.25 inch, and the power istypically about 125 mw to about 170 mw for a YAG (yttrium aluminumgarnet) type laser. In one embodiment, the balloon distal shaft sectionis heated so that the balloon material flows into at least a part of thespace between the proximal end of the tip member and the distal end ofthe catheter shaft. Alternatively, a removable spacer, configured to fitin the space between the inner tubular member and the tip member, may bedisposed between the distal end of the inner tubular member 21 and theproximal end of the tip member 14 during fusion bonding, or the fusionbonding heat may be controlled, such that the balloon material does notflow within the space between the inner tubular member 21 and the tipmember 14.

In the embodiments illustrated in FIGS. 2, 6 and 7, the outer surface ofthe balloon distal shaft section tapers distally to a smaller outerdiameter. In one embodiment, the taper in the balloon distal shaftsection 27 is formed during fusion bonding as the balloon polymericmaterial is heated and flows distally. Although not shown in thefigures, the portion 32 of the balloon distal shaft section 27 may havea dip, i.e., a concave surface, formed as the balloon polymeric materialflows into the space between the inner tubular member 27 and the tipmember 14.

To the extent not discussed above, the various catheter components maybe formed of conventional materials. The inner tubular member may beformed of a variety of conventional catheter shaft materials, includingPEBAX, Nylon, and high density polyethylene, used alone or in blends ormultilayered members. In a presently preferred embodiment, the innertubular member includes at least a layer of PEBAX having a ShoreDurometer hardness of about 60D to about 72D.

While the present invention is described herein in terms of certainpreferred embodiments, those skilled in the art will recognize thatvarious modifications and improvements may be made to the inventionwithout departing from the scope thereof. For example, althoughdiscussed primarily in terms of a catheter having an inner and outertubular member, it would be obvious to one of ordinary skill in the artthat the catheter shaft may alternatively have a dual lumen shaftdesign. Moreover, although individual features of one embodiment of theinvention may be discussed herein or shown in the drawings of the oneembodiment and not in other embodiments, it should be apparent thatindividual features of one embodiment may be combined with one or morefeatures of another embodiment or features from a plurality ofembodiments.

What is claimed is:
 1. A balloon catheter having a distal end,comprising: a) an elongated catheter shaft having a proximal end, adistal end, a proximal shaft section, a distal shaft section, aguidewire receiving lumen extending along at least a distal portion ofthe catheter shaft to a port at the catheter distal end, and aninflation lumen; b) a tip member located at a distal end of the catheterand having a proximal end spaced distally apart from the distal end ofthe elongated catheter shaft and defining a gap therebetween; and c) aballoon on the distal catheter shaft section and having an inflatableinterior in fluid communication with the inflation lumen, and a distalballoon shaft section having an extending portion with an interiorsurface extending longitudinally over the gap and defining at least inpart the guidewire receiving lumen.
 2. The catheter of claim 1 whereinthe balloon inflatable interior is spaced proximal to the distal end ofthe elongated shaft.
 3. The catheter of claim 1, wherein the tip memberhas a lumen extending therein in fluid communication with a lumen in theelongated shaft.
 4. The catheter of claim 1, wherein the tip member issofter than the catheter shaft.
 5. The catheter of claim 1, wherein thetip member is formed of a polymeric material having a Shore Durometerhardness lower than a Shore Durometer hardness of a polymeric materialforming at least a section of the catheter shaft.
 6. The catheter ofclaim 1, wherein the proximal end of the tip member is spaced apart fromthe distal end of the catheter shaft by about 0.05 to about 0.3 mm. 7.The balloon catheter of claim 1, including a sheath which is bonded tothe catheter shaft and the tip member, and which has a section extendingfrom the distal end of the catheter shaft to the proximal end of the tipmember.
 8. The balloon catheter of claim 1 wherein the balloon innersurface is bonded to an outer surface of the catheter shaft and an outersurface of the tip member.
 9. The balloon catheter of claim 1 whereinthe balloon distal shaft section has a tapered outer surface.
 10. Theballoon catheter of claim 1, wherein the extending portion of the distalballoon shaft section extends between a transverse surface of the distalend of the catheter shaft and a transverse surface of the proximal endof the tip member.
 11. The balloon catheter of claim 10, wherein theinner surface of the extending portion of the balloon distal shaftsection is substantially axially aligned with an inner surface of thetip member.
 12. The balloon catheter of claim 1 wherein the cathetershaft comprises an outer tubular member defining the inflation lumen andan inner tubular member disposed within at least a portion of the outertubular member and defining the guidewire lumen, wherein the distal endof the inner tubular member is spaced apart from the proximal end of thetip member.
 13. The balloon catheter of claim 12 wherein the distalballoon shaft section is secured to the inner tubular member.
 14. Aballoon catheter, comprising: a) an elongated catheter shaft having aproximal end, a distal end, an outer tubular member defining aninflation lumen, and an inner tubular member having a distal end anddisposed within at least a section of the outer tubular member anddefining a guidewire lumen; b) a tip member located at the distal end ofthe catheter and having a proximal end spaced distally apart from thedistal end of the inner tubular member and defining a gap therebetween;and c) a balloon on the distal catheter shaft section and having aninflatable interior in fluid communication with the inflation lumen, anda distal balloon shaft section having an extending portion with aninterior surface extending longitudinally over the gap and defining atleast in part the guidewire receiving lumen.